Operational excellence

io brings decades of project experience and cross-sector know-how from strategy to implementation to this complex field.

Operational Excellence: Holistic optimization of production, logistics and IT

We are at your side to support you in implementing your optimization measures on time and on budget. An important part of our philosophy for sustainably successful operational excellence projects is to involve your workforce and generate their enthusiasm about the defined methods at an early stage.

Installation of stacker cranes during operation at our client Häfele

Installation of the stacker cranes during operation at our client Häfele in Nagold.

Added value

Transparency across all structures and processes of the supply and value chain, production, and the logistics center results in long-term overall performance improvement

Optimum level of automation for physical and administrative processes defined

Support in controlling complex production processes and small batch sizes

Reduced throughput and idle times as well as enhanced product and process quality for greater economic efficiency

How we work

Employee draws something on a smartboard

Goal definition

Define the principal goals
Derive specific individual goals and key figures to measure project success
Compile strategic and external framework conditions

A meeting in the office with staff on video call

Initial situation analysis

Document existing processes and structures in detail
Perform a data-driven analysis
Determine level of maturity
Benchmarking (external and internal)

Employee wears VR goggles and tries out the virtual picking system

Solution development

Identify quick wins
Jointly identify and develop viable solutions and new approaches
Describe most promising optimization concepts in detail
Review the technical and organizational feasibility

Employees discuss a 3D model in the office

Business case and implementation

Provide economic evaluation of the solutions
Create an implementation plan
Provide decision-making support
Implement optimization measures

Core competencies in operational excellence

Optimization of the supply and value chain ×

Our work results in robust and responsive supply chains as well as cost- and transport-optimized network structures. We use methodical approaches to coordinate flows of goods and information to even out capacity fluctuations across the entire network.

Solutions

Strategically planned production and logistics networks
Strategies for procurement protocols and a sound basis prepared for make-or-buy decision-making
Supplier management: analysis and selection of suppliers, integrated material and information flow, supplier development
Digitalization of transport management and cross-plant synchronization of production, warehouse and transport, particularly in SAP environments

Production optimization ×

We consistently align our procedures and structures to the value-adding processes. Our team of experts analyze and optimize your production process as a whole system. This begins by making the system transparent for production staff and management alike. We help you minimize wastage to achieve maximum product and process quality. io takes a holistic approach, combining lean management and Six Sigma practices with innovative data mining methods.

Solutions

Comprehensive value stream analysis and system improvement through value stream design
Implementation of shop floor management and development as required
Product and process quality improvements using Six Sigma methods
Data and process mining utilization to optimize production
Enhanced plant efficiency by optimizing setup times and applying Total Productive Maintenance

Employees sorting goods in the warehouse

Optimization of intralogistics ×

Optimizing processes in intralogistics can counterbalance fluctuating order loads and reduce stock inventories. Improved transparency of processes and resources also facilitates more efficient staff allocation. Ensuring reliable supplies to and disposals from various functional areas improves overall performance. This shortens delivery times and improves delivery quality, thus sustainably improving customer satisfaction.

Solutions

Optimization of stock inventories and improved throughput
Demand-driven supplies and disposals introduced with contemporary means of transportation
Modernization of manual and automatic warehouse systems
Evaluation of logistics service providers performance
Introduction of a logistics dashboard
AI-based system load and staff allocation forecasting models

Innovation and digitalization ×

We utilize IT solutions to improve production, logistics and the supply chain, thus helping you align material flows and processes. Optimizing existing IT systems, control technologies and digital process flows will generate higher productivity and better quality. Besides improving various target values, we design clear roadmaps and modernization plans for your company and will help you identify and successfully apply relevant Industry 4.0 and artificial intelligence methodologies.

Solutions

End-to-end process digitalization
Automatic collection and real-time evaluation of key figures, and subsequent integration and virtualization utilizing the io Operations Management tool
Development of AI-based forecasting models
Modernization plans for IT and SAP systems
Customized Industry 4.0 and innovation roadmaps